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Structurally Optimized Inserts for Composite Lattice Core Sandwich Structures
Motivated by the potential to tailor the topology of high-performance composite lattice core sandwich structures, the goal of this thesis is to design and characterize structurally optimized inserts for local load introduction in novel composite lattice core sandwich panels developed at CMASLab.
Background: Owing to their outstanding structural performance, composite lattice structures are gaining increasing interest for use as sandwich core materials in high-performance aerospace applications. At CMASLab, ultra-lightweight lattice core sandwich structures made from carbon fiber reinforced thermoplastics are currently being developed and investigated for the use in aerospace. By virtue of their open cellular core architecture, these structures offer great potential for integrated functionality and load tailored design.
Motivation: To introduce local loads into sandwich panels (e.g. attachment of appendages and secondary structures), metallic inserts are typically required, which are embedded or bonded to the structure. As these inserts are a significant contributor to the overall structural mass, it is of great importance to develop efficient insert designs for increased structural performance. Given the novelty and outstanding performance of composite lattice core sandwich structures, the topic of insert design for such structures is of great relevance and has not been addressed so far. Combined with the tailorability of the lattice core, it is envisaged that the design freedom offered by additive manufacturing processes (e.g. SLM) enables the realization of highly efficient, structurally optimized inserts for optimum load introduction in composite lattice core sandwich panels.
Background: Owing to their outstanding structural performance, composite lattice structures are gaining increasing interest for use as sandwich core materials in high-performance aerospace applications. At CMASLab, ultra-lightweight lattice core sandwich structures made from carbon fiber reinforced thermoplastics are currently being developed and investigated for the use in aerospace. By virtue of their open cellular core architecture, these structures offer great potential for integrated functionality and load tailored design.
Motivation: To introduce local loads into sandwich panels (e.g. attachment of appendages and secondary structures), metallic inserts are typically required, which are embedded or bonded to the structure. As these inserts are a significant contributor to the overall structural mass, it is of great importance to develop efficient insert designs for increased structural performance. Given the novelty and outstanding performance of composite lattice core sandwich structures, the topic of insert design for such structures is of great relevance and has not been addressed so far. Combined with the tailorability of the lattice core, it is envisaged that the design freedom offered by additive manufacturing processes (e.g. SLM) enables the realization of highly efficient, structurally optimized inserts for optimum load introduction in composite lattice core sandwich panels.
The goal of this thesis is to design and characterize structurally optimized inserts for local load introduction in composite lattice core sandwich panels.The major tasks are:
• Literature research on insert design and analysis, fabrication processes, and topology optimization
• Identification and characterization of efficient bonding methods for metallic parts with carbon fiber reinforced thermoplastics, considering different fabrication processes (milling, additive manufacturing, etc.)
• Design of structurally optimized insert concepts for load introduction into composite lattice core sandwich panels, following a topology optimization procedure.
• Fabrication of the optimized inserts and integration into the composite lattice core sandwich panel using the developed bonding technique.
• Numerical and experimental investigation of the structural performance of the developed insert design for representative load cases (pull-out & shear).
The goal of this thesis is to design and characterize structurally optimized inserts for local load introduction in composite lattice core sandwich panels.The major tasks are: • Literature research on insert design and analysis, fabrication processes, and topology optimization • Identification and characterization of efficient bonding methods for metallic parts with carbon fiber reinforced thermoplastics, considering different fabrication processes (milling, additive manufacturing, etc.) • Design of structurally optimized insert concepts for load introduction into composite lattice core sandwich panels, following a topology optimization procedure. • Fabrication of the optimized inserts and integration into the composite lattice core sandwich panel using the developed bonding technique. • Numerical and experimental investigation of the structural performance of the developed insert design for representative load cases (pull-out & shear).
Christoph Karl
ETH Zurich - CMASLab
Leonhardstr. 21, LEE O225
8092 Zurich, Switzerland
tel: +41 44 632 0840
email: karlc@ethz.ch
Christoph Karl ETH Zurich - CMASLab Leonhardstr. 21, LEE O225 8092 Zurich, Switzerland tel: +41 44 632 0840 email: karlc@ethz.ch